Split motor winding structure

Abstract

A split motor winding structure, comprising: a modular core; and a distributed lap winding formed by stacking a plurality of coils. A plurality of slots are formed in the modular core, and the plurality of coils are inserted into the slots. At edges of the modular core, there are a plurality of slots that do not have coils inserted therein, and said slots are filled with dummy slot insulating blocks. The split motor winding structure provided by the present application has a simple structure, wide applicability, and high market competitiveness in terms of costs.

Description

A split motor winding structure

[0001] This application claims priority to the Chinese patent application filed with the China Patent Office on December 21, 2023, with application number 202311774547.2 and invention name “A Split Motor Winding Structure”, the entire contents of which are incorporated by reference into this application. Technical Field

[0002] The present application relates to the field of motor technology, and in particular to a split-flap motor winding structure. Background Art

[0003] With the increasing size of motors, a series of technical challenges have emerged, including the need for larger manufacturing equipment, transportation difficulties, and high maintenance costs. Split-segment motors, however, can separate large components like the stator and rotor into modules, which are then assembled into a motor. This effectively addresses these technical challenges, including manufacturing, transportation, and maintenance. However, split-segment motor technology was developed earlier abroad, and the domestic market for split-segment motor winding structures is largely imported, resulting in high costs. Existing split-segment windings utilize full-pitch windings, with the coils formed from multiple turns of flat-wound copper wire. This places high demands on the coil winding process and its shape. Flat-wound copper wire is difficult to form, significantly limiting the wire gauge and aspect ratio. Furthermore, the flat-wound process is highly susceptible to damage to the copper wire's outer insulation, placing high demands on the forming equipment and inefficient mass production. Consequently, the existing structure's winding insulation performance is difficult to guarantee, resulting in high production costs and limiting the development of split-segment motors. Therefore, the domestic market urgently needs to develop new split-segment motor winding structures.

[0004] Summary of the Invention

[0005] In order to solve the above technical problems, the present invention provides a split-petal motor winding structure, in which the winding adopts the traditional distributed stacking winding. At the same time, the stator split is matched with a virtual slot filling structure, and the slot is matched with a suitable insulation structure, thereby realizing the split-petal processing of the stator winding, which can greatly reduce the manufacturing cost and has higher reliability.

[0006] The technical solutions provided by the present invention are as follows:

[0007] A split motor winding structure includes a modular iron core and a distributed stacked winding consisting of a plurality of stacked coils. The modular iron core is provided with a plurality of slots, in which a plurality of coils are embedded. There are a plurality of slots at the edge of the modular iron core without coils embedded, and the slots are filled with virtual slot insulating blocks.

[0008] Preferably, an interlayer spacer is provided between two adjacent coils.

[0009] Preferably, the slots of the modular core are filled with slot wedges.

[0010] Preferably, the number and distribution of the virtual slot insulating blocks located at the edge of each module core can be adjusted according to actual needs.

[0011] Preferably, the virtual slot insulating blocks located at the edges of the adjacent module cores are respectively located in the upper and lower parts of the space under the slot wedge in the slot, and the other half of the slot where the virtual slot insulating blocks are installed is filled with a straight edge of the coil.

[0012] Preferably, the coil includes two straight edges at a certain angle, and the two straight edges are spatially distributed by twisting the nose, and can be inserted into the slot according to the module core slot type. One straight edge is embedded in the lower half of the module core slot, called the lower layer edge of the coil, and the other edge is embedded in the upper layer of the module core slot, called the upper layer edge of the coil.

[0013] Preferably, the two straight edges of the coil located in the middle of the module core are embedded in the slot, the upper edge in the same slot is the straight edge of one coil, and the lower edge is the straight edge of another coil, and the slot is filled with the upper and lower edges of different coils; the slot located at the edge of the module core has only one straight edge of the coil, and the other part is filled with a virtual slot insulation block.

[0014] Preferably, the structure of the virtual slot insulating block is consistent with the partial structure of the coil in the slot.

[0015] Preferably, the modular core is formed by stacking a number of sector-shaped sheets.

[0016] This application has the following advantages over the prior art:

[0017] The split motor winding structure of the present application is relatively simple and has strong versatility. It has low requirements for production equipment and transportation, is easy to achieve mass production, facilitates subsequent product operation and maintenance, and has strong market competitiveness. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments recorded in this application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0019] FIG1 is a schematic structural diagram of a split-flap motor winding structure according to an embodiment of the present invention;

[0020] FIG2 is a cross-sectional view of a split-flap motor winding structure according to an embodiment of the present invention;

[0021] FIG3 is a schematic structural diagram of a coil according to an embodiment of the present invention;

[0022] FIG4 is a schematic structural diagram of a module core according to an embodiment of the present invention;

[0023] FIG5 is a schematic structural diagram of a virtual groove insulating block according to an embodiment of the present invention;

[0024] FIG6 is a schematic diagram of the structure of the slot wedge in an embodiment of the present invention.

[0025] Reference numerals: 1. modular core; 2. coil; 3. virtual slot insulation block; 4. interlayer spacer; 5. slot wedge. DETAILED DESCRIPTION

[0026] In order to help those skilled in the art better understand the technical solutions in this application, the technical solutions in the embodiments of this application will be clearly and completely described below. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without making any creative efforts shall fall within the scope of protection of this application.

[0027] As shown in Figures 1-5, an embodiment of the present invention provides a split motor winding structure, including a modular core 1 and a distributed stacked winding composed of a plurality of stacked coils 2. The modular core 1 is formed by stacking a plurality of fan-shaped sheets. A plurality of slots are provided on the modular core 1, and a plurality of coils 2 are embedded in the slots. An interlayer spacer 4 is provided between two adjacent coils 2. The span of the coil 2 and the slot of the modular core 1 are designed to match to ensure that the upper and lower edges of each coil 2 are fully embedded in the modular core 1. Due to the use of a distributed stacked winding, the slots at both ends of the modular core 1 are only embedded in one edge of the coil 2. There are a plurality of slots at the edge of the modular core 1 without coils 2 embedded. The slots are filled with virtual slot insulating blocks 3. The structure of the virtual slot insulating blocks 3 is consistent with the partial structure of the coil 2 in the slot, and the slots of the modular core 1 are filled with slot wedges 5.

[0028] In this embodiment, the distributed stacked winding is a traditional stacked winding coil structure, one side of the coil 2 (the straight side of the coil 2) is embedded in the upper side of the slot of the module core 1, and the other side of the coil 2 (the straight side of the coil) is embedded in the lower side of the slot of the module core 1, and is cyclically embedded in the module core 1. There will be empty slots on the edge of the module core 1 that cannot be filled by the coil 2, and the structure of the virtual slot insulating block 3 is similar to the outer cross-sectional area of ​​the straight side of the coil 2 and the interlayer gasket embedded in the module core 1. It can replace one side of the straight side of the coil 2 and the interlayer gasket 4 to be embedded in the module core 1, filling the empty slot on the edge of the module core 1, ensuring that the entire slot is the same as the slots on the upper and lower layers of the coil 2. After the slot wedge 5 is inserted, the coil 2 in the slot can be fixed normally, thereby realizing the petal division of the winding.

[0029] In this embodiment, the number and distribution of the dummy slot insulating blocks 3 located at the edge of each modular core 1 can be adjusted according to actual needs. The dummy slot insulating blocks 3 located at the edges of adjacent modular cores 1 are located in the upper and lower portions of the space below the slot wedge 5 within the slot, respectively. The other half of the slot where the dummy slot insulating blocks 3 are installed is filled by a straight edge of the coil 2.

[0030] In this embodiment, coil 2 comprises two linear edges at a certain angle, spatially distributed through nose twisting. These edges can be slotted according to the slot profile of modular core 1. One linear edge is embedded in the lower half of the slot of modular core 1, referred to as the coil's lower edge, while the other edge is embedded in the upper layer of the slot of modular core 1, referred to as the coil's upper edge. Coil 2 located in the middle of modular core 1 has two linear edges embedded in the slot. Within the same slot, the upper edge represents one coil's linear edge, while the lower edge represents another coil's linear edge. The slot is filled with both upper and lower edges of different coils. Slots located at the edges of modular core 1 contain only one coil's linear edge, with the remaining portion filled with virtual slot insulation blocks 3.

[0031] The split motor winding structure in this embodiment is mainly composed of distributed stacked windings and virtual slot insulating blocks 3. The size and end shape of the coil 2 can be adjusted according to actual conditions. The material, shape, and quantity of the virtual slot insulating blocks 3 filling the virtual slot can be adjusted according to needs. It can be a solid structure or a hollow structure. The material and shape of the interlayer spacers 4 and slot wedges 5 can be adjusted according to needs.

[0032] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A split motor winding structure, characterized in that, It includes a modular iron core (1) and a distributed stacked winding composed of several coils (2) stacked. A number of slots are provided on the modular iron core (1), and several of the coils (2) are embedded in the slots. There are several slots without coils (2) embedded at the edge of the modular iron core (1), and the slots are filled with dummy slot insulation blocks (3).

2. The split motor winding structure according to claim 1, wherein Interlayer spacers (4) are provided between two adjacent coils (2).

3. The split motor winding structure according to claim 1, characterized in that, The slot openings of the modular iron core (1) are filled with slot wedges (5).

4. The split motor winding structure according to claim 1, characterized in that, The number and distribution of the dummy slot insulation blocks (3) at the edge of each modular iron core (1) can be adjusted according to actual requirements.

5. The split motor winding structure according to claim 1, characterized in that, The adjacent dummy slot insulation blocks (3) at the edge of the modular iron core (1) are respectively located in the upper and lower parts of the space under the slot wedges (5) in the slot. The other half of the slot where the dummy slot insulation block (3) is installed is filled by a straight side of the coil (2).

6. The split motor winding structure according to any one of claims 1-5, characterized in that, The coil (2) includes two straight sides at a certain angle, and the two straight sides achieve spatial distribution through nose torsion and can be inserted into the slot according to the slot shape of the modular iron core (1). One straight side is embedded in the lower half of the slot of the modular iron core (1), which is called the lower layer side of the coil, and the other side is embedded in the upper layer of the slot of the modular iron core (1), which is called the upper layer side of the coil.

7. The split motor winding structure according to claim 6, characterized in that, The two straight sides of the coil (2) in the middle of the modular iron core (1) are embedded in the slot. The upper layer side in the same slot is a straight side of one coil, and the lower layer side is a straight side of another coil. The upper and lower layer sides of different coils are filled in the slot; there is only one straight side of the coil in the slot at the edge of the modular iron core (1), and the other part is filled with the dummy slot insulation block (3).

8. The split motor winding structure according to any one of claims 1-5, characterized in that, The structure of the dummy slot insulation block (3) is consistent with a part of the structure of the coil (2) in the slot.

9. The split motor winding structure according to any one of claims 1-5, characterized in that The modular iron core (1) is formed by stacking a number of sector-shaped sheets.

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